System and method for gas reaction

ABSTRACT

Herein disclosed is an apparatus having a first porous rotor positioned about an axis of rotation, wherein the first porous rotor comprises a first catalyst; an outer casing, wherein the outer casing and the first porous rotor are separated by an annular space; and a motor configured for rotating the first porous rotor about the axis of rotation.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of U.S. Ser. No.12/706,468 filed on Feb. 16, 2010, which application claims the benefitunder 35 U.S.C. §119(e) of U.S. Provisional Patent Application Ser. No.61/154,197 filed Feb. 20, 2009, said applications being incorporatedherein by reference in their entirety for all purposes.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

BACKGROUND OF THE INVENTION

1. Technical Field

The present invention generally relates to production of desired productvia reaction of gases. More specifically, the present invention relatesto reaction of gases via centrifugation. Even more specifically, thepresent invention relates to enhanced reaction of gases via catalyticcentrifugation.

2. Background of the Invention

The rate and extent of chemical reactions are limited by the laws ofkinetics and thermodynamics. The rate of reaction is dependent on manythings, including time, temperature, and pressure. In the case ofcatalyzed reactions there is the additional rate limiting factor of thecontact time of the reactants with the catalyst and the time for reactedproducts to be removed from the surface of the catalyst to enable thecatalyst to catalyze further reactants.

In conventional reactors, contact time for the reactants and catalyst isoften controlled by mixing which provides contact between componentsinvolved in a chemical reaction. There have been various innovationsdirected towards maximizing the use of mixing and mixing devices toaccelerate chemical reactions. High shear and high energy mixing deviceshave been proposed for enhancing the rate of chemical reactions.

There have been other devices proposed for accelerating the reactions ofchemical reactants. For example, there has been prior disclosure onmethods of accelerating chemical reactions through the use ofhydrodynamic cavitation. Hydrodynamic cavitation involves phase changeand rapid increases in temperatures and pressures; pressure variationcaused by the variation in the flowing liquid velocity results inaccelerated chemical reaction.

There is a need in the art for efficient and economical apparatus andmethods of reacting gaseous components to produce a desired product.Desirably, the conversion of energy to reaction is maximized via thedisclosed system and method.

SUMMARY

Herein disclosed is an apparatus, which comprises (1) a firstcylindrical, porous, catalytic rotor symmetrically positioned about anaxis of rotation and surrounding a first interior space; wherein thefirst porous catalytic rotor comprises a first catalyst; (2) an outercasing, wherein the outer casing and the rotor are separated by anannular space; (3) a motor configured for rotating the rotor about theaxis of rotation; (4) a feed inlet line; and (5) a first outlet line,wherein the first outlet line is fluidly connected with the annularspace. In embodiments, the feed inlet line of the apparatus is fluidlyconnected with the first interior space. In some embodiments, the feedinlet line extends into the first interior space. In some cases, thefeed inlet line extends into a vertically central portion of the firstinterior space. In some other cases, the feed inlet line extends to aposition within the first interior space proximal the axis of rotation.

In embodiments, the rotor of the apparatus is substantially tubular. Inembodiments, the first porous catalytic rotor of the apparatus is madefrom or comprises a selectively permeable material. In some cases, theselectively-permeable material is made with, impregnated or coated witha catalyst. In some other cases, the selectively-permeable materialcomprises sintered metal or ceramic. In embodiments, the first porous,catalytic rotor has a diameter in the range of from about 4 to about 12inches. In embodiments, the first porous, catalytic rotor has a lengthin the range of from about 8 to about 20 inches. In embodiments, themotor of the apparatus is capable of providing a rotational frequency ofthe rotor of up to at least 7,500 RPM.

In certain embodiments, the apparatus further comprises a second porouscatalytic rotor concentric with the first porous catalytic rotor andsurrounding a second interior space, wherein the second porous catalyticrotor comprises a second catalyst. In embodiments, the feed inlet lineis fluidly connected with the first interior space. In some certainembodiments, the apparatus further comprises a second outlet, whereinthe second outlet line is fluidly connected with the second interiorspace. In certain embodiments, the first catalyst and the secondcatalyst of the apparatus are the same. In certain other embodiments,the first catalyst and the second catalyst of the apparatus aredifferent. Another aspect of the disclosure includes a system thatcomprises a plurality of the apparatus as described. In someembodiments, the porous, catalytic rotor of a first apparatus of thesystem has a different catalytic functionality than the porous,catalytic rotor of a second apparatus.

Herein disclosed is also a method of producing a product of a gaseousreaction. The method comprises (1) passing a feed gas comprising atleast one gaseous reactant through a porous, catalytic rotor from aninlet side of the rotor, wherein the porous, catalytic rotor ispermeable to the at least one gaseous reactant and is made from orcontains a catalyst effective for catalyzing a first reaction; and (2)extracting a first desired product from the outlet side of the rotor. Inembodiments, the method further comprises rotating the porous, catalyticrotor about an axis of rotation at a rotational frequency. Inembodiments, the rotor is cylindrical. In certain embodiments, theporous, catalytic rotor comprises sintered metal or ceramic. Inembodiments, the sintered metal or ceramic is made with, impregnated byor coated with catalyst.

In certain embodiments, the disclosed method further comprises passingthe desired product through a second porous, catalytic rotor from aninlet side of the second porous, catalytic rotor, wherein the secondporous, catalytic rotor is permeable to the first desired product and ismade from or contains a catalyst effective for catalyzing a seconddesired reaction. In some cases, the first porous, catalytic rotor andthe second porous, catalytic rotor are comprised in a single apparatus.In some other cases, the first porous, catalytic rotor and the secondporous, catalytic rotor are contained in two separate apparatus.

Embodiments disclosed herein may pertain to an apparatus having a firstporous rotor positioned about an axis of rotation, wherein the firstporous rotor comprises a first catalyst; an outer casing, wherein theouter casing and the first porous rotor are separated by an annularspace; and a motor configured for rotating the first porous rotor aboutthe axis of rotation. The apparatus may also include a feed inlet line;and a first outlet line.

In some aspects, the first outlet line is in fluid communication withthe annular space. In other aspects, the feed inlet line is fluidlyconnected with the interior space, and wherein the first porous rotor ispositioned surrounding an interior space. The first porous rotor may bea selectively permeable material. In one embodiments, theselectively-permeable material is made with, impregnated with, or coatedwith an additional catalyst. In another embodiment, theselectively-permeable material comprises sintered metal or ceramic.

The apparatus may include the feed inlet line extending into theinterior space. In on aspect, the feed inlet line extends into avertically central portion of the interior space. The apparatus mayinclude a second porous rotor concentric with the first porous rotor,wherein the second porous rotor comprises a second catalyst. There maybe feed inlet line fluidly connected with the interior space, and thesecond porous rotor may be positioned surrounding a second interiorspace. The apparatus may also include an outlet line, wherein the outletline is fluidly connected with the second interior space. In someaspects, the first catalyst and the second catalyst are the same. Inother aspects, the first catalyst and the second catalyst are different.

Embodiments may pertain to a system having a plurality of apparatusesdisclosed herein.

Other embodiments may pertain to a method of producing a product of agaseous reaction that includes the steps of contacting a feed gascomprising at least one gaseous reactant with a rotor wherein the rotoris permeable to the at least one gaseous reactant, and wherein the rotorcomprises a catalyst effective for catalyzing the gaseous reaction; andextracting the product from an outlet side of the rotor. The method mayinclude rotating the rotor about an axis of rotation at a rotationalfrequency.

The method may also include passing the product through a second rotorfrom an inlet side, wherein the second rotor is permeable to theproduct, and wherein the second rotor is made from or containsadditional catalyst effective for catalyzing a second reaction.

In some aspects, the rotor is cylindrical and porous. In other aspects,rotor comprises sintered metal or ceramic. The sintered metal or ceramicmay be made with, impregnated with, or coated with catalyst.

These and other embodiments and potential advantages will be apparent inthe following detailed description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more detailed description of the preferred embodiment of thepresent invention, reference will now be made to the accompanyingdrawings, wherein:

FIG. 1 is a schematic of a system according to an embodiment of thisdisclosure.

FIG. 2 is a schematic of a system according to another embodiment ofthis disclosure.

FIG. 3A is a schematic of a system according to another embodiment ofthis disclosure.

FIG. 3B is a schematic of a system according to another embodiment ofthis disclosure.

FIG. 3C is a schematic of a system according to another embodiment ofthis disclosure.

In the figures, like numerals are used to refer to like components.

NOTATION AND NOMENCLATURE

As used herein, the terms “reactive centrifuge” and “catalyticcentrifuge” when used in reference to an apparatus of this disclosureare used to indicate that the apparatus is configured for integration ofcentrifugation with catalytic functionality.

The phrase, “porous, catalytic rotor” as used herein refers to a rotorwhich is not impermeable to gas and which is made of or contains thereinat least one catalytic material.

DETAILED DESCRIPTION

I. Overview. Herein disclosed are a system and method of reactinggaseous components to produce a desired product. The disclosed systemand method provide for integration of centrifugation with catalysis,enhancing gas phase reaction to produce a desired product. Althoughdescribed hereinbelow with respect to a porous, catalytic rotor, it isenvisaged that, in applications, the centrifugation itself will besufficient to allow a desired reaction, and, in such instances, theporous rotor may not be made from or contain therein catalyst. Thesystem and method are applicable to any number of a wide variety ofreactions for which reactants can be provided in gas phase (or convertedthereto within the reactor) and/or for which suitable catalyst isavailable. Introducing a non homogenous catalyst, including abrasiveones, via the feed of a rotating high shear reactor can cause severeabrasion of the reactor parts. The system of this disclosure overcomesthis by eliminating or minimizing the need for abrasive catalyst in thefeed stream by, in embodiments, placing catalytic surfaces at the pointwhere cavitation conditions are likely to exist.

II. System for Gas Reaction. The reactive centrifugation system of thisdisclosure comprises at least one catalytic centrifuge. The at least onecatalytic centrifuge comprises at least one porous, catalytic rotor. Asystem for gas reaction according to this disclosure will now bedescribed with reference to FIG. 1. FIG. 1 is a schematic of a reactivecentrifugation system 100 according to an embodiment of this disclosure.Reactive centrifugation system 100 comprises catalytic centrifuge 110.

Each of the one or more catalytic centrifuges of the disclosed systemcomprises an outer casing, at least one porous, catalytic rotor, atleast one feed inlet line, and at least one product outlet line. In theembodiment of FIG. 1, catalytic centrifuge 110 comprises outer casing165, catalytic rotor 185, feed inlet line 120, and product outlet line190.

Each of the one or more catalytic centrifuges of the disclosed systemcomprises an outer casing. As indicated in FIG. 1, outer casing 165surrounds rotor 185. Outer casing 165 may be cylindrical on its outerand/or inner surfaces. Outer casing 165 can be made out of specificmaterials to prevent harmful materials from hurting users of thecatalytic centrifuge. In applications, components of catalyticcentrifuge 110, such as casing 165, are made of stainless steel. Byproviding an enclosed vessel, the temperature and pressure within eachcatalytic centrifuge are adjusted as desired within design limitations.Catalytic centrifuge 110 may be operable at pressures up to at least 15psig, 500 psig, 1000 psig or 1455 psig. Catalytic centrifuge 110 may beoperable at pressures up to 100 atm. Catalytic centrifuge 110 may beoperable at temperatures up to 150° C., 200° C., 250° C., 300° C., 400°C., 450° C., 500° C., 550° C., or up to about 600° C.

Each of the one or more catalytic centrifuges comprises at least oneporous catalytic rotor. As indicated in the embodiment of FIG. 1, porouscatalytic rotor 185 is symmetrically positioned within casing 165 aboutan axis of rotation 103. The porous catalytic rotor 185 is positionedwithin outer casing 165 such that a clearance or annular space 105 iscreated between outer wall 186 of catalytic rotor 185 and the innersurface of outer casing 165. Rotor 185 surrounds an interior space 122configured such that the interior space 122 may be evacuated of airprior to use to provide near frictionless rotation when operating.

FIG. 2 is a schematic of a system 200 according to another embodiment ofthis disclosure. System 200 comprises catalytic centrifuge 210.Catalytic centrifuge 210 comprises outer casing 265, inner porouscatalytic rotor 285A, outer porous catalytic rotor 285B, feed inlet line220, product outlet line 290. Outer porous catalytic rotor 285B ispositioned within outer casing 265 such that a clearance or annularspace 205 is created between outer wall 286B of outer porous catalyticrotor 285B and the inner surface of outer casing 265. Inner porouscatalytic rotor 285A is separated by an interior space 222B from outerporous catalytic rotor 285B and surrounds an interior space 222A.Interior spaces 222A and 222B may be configured such that the interiorspaces can be evacuated of air prior to use to provide near frictionlessrotation when operating.

FIGS. 3A-3C provide schematics of embodiments of systems according tothis disclosure wherein the catalytic centrifuge comprises two rotorsand an additional inlet line or an additional outlet line. The systems300, 300′, 300″ of FIGS. 3A, 3B, and 3C respectively comprise catalyticcentrifuges 310, 310′, and 310″. Catalytic centrifuge comprises outercasing 365 (365′, 365″), inner porous catalytic rotor 385A (385A′,385A″), outer porous catalytic rotor 385B (385B′, 385B″), feed inletline 320 (320′, 320″), product outlet line 390 (390′, 390″). Outerporous catalytic rotor 385B (385B′, 385B″) is positioned within outercasing 365 (365′, 365″) such that a clearance or annular space 305(305′, 305″) is created between outer wall 386B (386B′, 386B″) of outerporous catalytic rotor 385B (385B′, 385B″) and the inner surface ofouter casing 365 (365′, 365″). Inner porous catalytic rotor 385A (385A′,385A″) is separated by an interior space 322B (322B′, 322B″) from outerporous catalytic rotor 385B (385B′, 385B″) and surrounds an interiorspace 322A (322A′, 322A″). Interior spaces 322A (322A′, 322A″) and 322B(322B′, 322B″) may be configured such that the interior spaces can beevacuated of air prior to use to provide near frictionless rotation whenoperating.

Porous Catalytic Rotor. The porous catalytic rotor may be tubular inshape, e.g. a sintered metal tube. The porous catalytic rotor (185,285A, 285B, 385A, 385B, 385A′, 385B′, 385A″, 385B″) is designed suchthat it is permeable to gaseous components and may provide at least onecatalytic functionality. The porous catalytic rotor may comprise orcontain sintered metal. The rotor may be made of or may contain apermeable material. The permeable material may be tailored for a desiredpore size and porosity having integral strength to withstand a desiredoperational rotation. In applications, the rotor comprises carbon fiber.In applications, the rotor also has catalytic functionality. In suchembodiments, the rotor is made from or contains therein at least onecatalytic metal or metal salt.

In embodiments, a catalytic permeable material 187 is sandwiched betweenan outer support 186 and an inner support 188 of rotor 185. For exampleouter wall 186 and inner wall 188 of rotor 185 may be a supportmaterial. For example, the porous catalytic material of rotor 185 may besandwiched between supports to provide increased strength thereto. Theinner and outer supports may resemble a basket of support material inwhich the porous catalytic material is sandwiched. The inner and outersupports may be configured as a mesh basket (e.g., a stainless steelmesh basket) in which the porous catalytic material is sandwiched. Theinner and outer supports may be any material known to provide supportand through which gas may readily pass. Top 189 (289, 389A, 389B, 389K,389W, 389K′, 389B″) and bottom 184 (284, 384′, 384″) of rotor 185 (285,385A, 385B, 385A′, 386B′, 385A″, 385B″) may be impermeable, or may beporous catalytic material. The bottom of the inner and outer rotors mayor may not be integrated.

In embodiments, the porous catalytic material is formed by placing metalpowder, e.g. stainless steel powder, in a mold and pressing it underhigh pressure. In embodiments, pressures of greater than 20,000 psig areutilized to compress the powder and form the porous material. Inembodiments, pressures of greater than 50,000 psig are utilized tocompress the powder and form the porous material. In embodiments,pressures of up to 150,000 psig are utilized to compress the powder andform the porous material. Pressing may reduce the thickness of astarting powder by at least 60%. The pressed material may then becalcined in an oven. To avoid shrinkage during formation, the materialmay be brought to a temperature approaching, but less than, the melttemperature, and cool down may be controlled over a sufficient durationto avoid/minimize shrinkage. Control of temperature during formation ofthe porous catalytic material of the rotor may also hinder the formationof oxides.

Catalyst functionality may be provided to the rotor by adding one ormore catalyst metal or metal salt to the powder prior to pressing. Forexample, one or more catalytic material may be added to a metal powder,calcined, and then pressed to make the sintered material. Alternatively,catalyst functionality can be added following formation of the porousmaterial. For example, in embodiments, a sintered material is formed andthen coated or impregnated with one or more metal catalyst. Theimpregnated material may then be calcined.

The porous material of the rotor may be custom-tailored to provide gasflow paths of a desired tortuousity, porosity (density) and average poresize of the material. For example, a powder may be pressed into ahoneycomb structure or wax added and subsequently calcined to remove thehoneycomb or wax structure and leave honeycomb- or other patternedtailored paths or voids within the porous material of the rotor. Forexample, a loofah sponge or a synthetic sponge is placed in a metalcasing/support, a catalyst powder is pressed into the casing/supportwithin which is the sponge. Then the sponge is removed by calcining thecasing so that a porous catalytic rotor is formed with voids and pathsand channels defined by the sponge placed within. It is contemplatedthat any sponge or lacy structure may be used in this manner toconstruct the porous catalytic material for the rotor—organic orinorganic, synthetic or natural. In some embodiments, the porouscatalytic rotor has voids, and/or paths, and/or channels that areregular. In some other embodiments, the porous catalytic rotor hasvoids, and/or paths, and/or channels that are random. In embodiments,the desired surface contact area of gaseous reactant(s) with thecatalyst during operation of the reactive centrifuge is obtained by theconstruction of the porous catalytic rotor, which is custom-tailored foreach specific application/reaction.

Suitable material from which the porous rotor may be formed is, forexample, ceramic or stainless steel. In embodiments, the porous materialcomprises 316 stainless steel. In embodiments, the density of theselectively-permeable material is in the range of from about 3 g/cm³ toabout 6 g/cm³. In applications, the density of the selectively-permeablematerial is greater than about 3 g/cm³, 3.5 g/cm³, 4 g/cm³, 4.5 g/cm³, 5g/cm³, or 6 g/cm³. In applications, the density of the selectivelypermeable material is about 3.5 g/cm³, 4 g/cm³, 4.5 g/cm³, 5 g/cm³, or5.5 g/cm³. In embodiments, the average pore size of the selectivelypermeable material is less than about 200 μm, less than about 50 μm,less than about 20 μm, less than about 10 μm, less than about 5 μm, lessthan about 3 μm, less than about 1 μm, or less than about 0.5 μm. Inembodiments, the average pore size is in the range of Angstroms.

Each porous catalytic rotor may have a diameter and length determined tobe suitable for a certain application, and the reactive centrifuge mayhave any desired nominal size. As such, the dimensions given are notmeant to be limiting. In applications, each porous catalytic rotor mayhave a diameter in the range of from about 2 inches to about 12 inches,from about 4 inches to about 10 inches, from about 4 inches to about 8inches, or from about 4 inches to about 6 inches. The rotor may have avertical length in the range of from about 8 inches to about 20 inches,from about 10 inches to about 17 inches, or from about 12 inches toabout 15 inches. The nominal capacity of the reactive centrifuge 110,210, 310 may be about 10 gallons, about 5 gallons, or about 1 gallon.The thickness of the porous catalytic material may be tailored toprovide a desired surface area. In embodiments, the porous catalyticmaterial or rotor has a thickness of about ¼-inch, about ½-inch, about¾-inch, or about 1-inch.

A desired permeability or average pore size may be obtained by providinga sintered material of a certain pore size (e.g., 30 to 100 μm) andsubsequently treating the sintered material with molecular sieve ormembrane. The external surfaces of the sintered metal material may becovered with one or more layers of molecular sieve. Suitable molecularsieves include, without limitation, carbon sieves, ALPOS, SAPOS,silicas, titanium silicates, and zeolites. In embodiments, the molecularsieve has a pore size in the range of from 3 angstrom (Å) to about 20 Å(about 0.3 nm to about 2 nm). The coating may be applied via methodssimilar to methods utilized to prepare catalyst surfaces on monolithand/or honeycomb catalytic converters that are used on automobilemufflers.

Rotor 185 provides catalytic functionality to catalytic centrifuge 185.Rotor 185 is made from or contains therein one or more catalyst. Thecatalyst may be integrated into the porous material during formationthereof, or applied to and/or within the porous material followingformation thereof. In embodiments, porous catalytic rotor 185 comprisesa sintered material (or a sintered material coated with molecular sieve)impregnated or coated with one or more catalyst. The catalyst may beselected from elemental metals and metal salts. The catalyst with whichthe sintered material is impregnated or coated or co-formed may be anysuitable catalyst, for example, a palladium silica catalyst or platinumsilica catalyst. In applications, the catalyst is functional forconversion of light gas to higher hydrocarbons. The disclosed systemcould also benefit other chemical reactions involving gases or liquidswhere high shear induces cavitation resulting in extreme temperaturesand pressures in the presence of a catalytic surface.

The at least one catalytic centrifuge of the disclosed system furthercomprises at least one feed inlet line. System 100 of the embodiment ofFIG. 1 comprises feed inlet line 120. Feed inlet line 120 is configuredto introduce feed gas into the interior space 122 defined by porouscatalytic rotor 185. One end 125 of feed inlet line 120 is in fluidcommunication with interior space 122 of catalytic centrifuge 110. Inembodiments, outlet end 125 of feed inlet line 120 is positioned withina vertically central portion of interior space 122. Desirably, outletend 125 is positioned proximal to axis of rotation 103. The other end offeed inlet line 120 is configured for introduction of reactant feed gasinto interior region 122 delineated by rotor 185. In embodiments, theoutlet end 125 and/or the other (inlet) end of feed inlet line 120 has adiameter of ½ inch, ¾ inch, or 1-inch.

In the embodiment of FIG. 2, system 200 comprises feed inlet line 220.Feed inlet line 220 is configured to introduce feed gas into theinterior space 222A defined by porous catalytic rotor 285A. One end 225of feed inlet line 220 is in fluid communication with interior space222A of catalytic centrifuge 210. In embodiments, outlet end 225 of feedinlet line 220 is positioned within a vertically central portion ofinterior space 222A. Desirably, outlet end 225 is positioned proximal toaxis of rotation 203. In embodiments, the outlet (225) and/or the other(inlet) end of feed inlet line 220 has a diameter of ½ inch, ¾ inch, or1-inch.

As indicated in FIG. 3A, the feed inlet line of a system 300 accordingto this disclosure may comprise a feed inlet line 320 in fluidcommunication with interior space 322B between outer wall 386A of innerporous catalytic rotor 385A and inner wall 388B of outer porouscatalytic rotor 385B. In embodiments, the outlet end 325 of feed inletline 320 is positioned below top 389B of outer rotor 385B. Inembodiments, the outlet end 325 of feed inlet line 320 is positionedbelow top 389A of outer rotor 385A. In embodiments, the outlet end 325of feed inlet line 320 is vertically positioned above top 389A of innerrotor 385A and below top 389B of outer rotor 385B. In embodiments,outlet end 325 of feed inlet line 320 is positioned between outer wall386A of inner rotor 385A and inner wall 388B of outer rotor 385B. Inembodiments, the outlet and/or the other (inlet) end of feed inlet line320 has a diameter of ½ inch, ¾ inch, or 1-inch.

A catalytic centrifuge of a gas reaction system according to thisdisclosure may further comprise one or more additional inlet lines. Asindicated in FIG. 3B, a system 300′ according to an embodiment comprisesfeed inlet line 320′ configured to introduce feed gas into the interiorspace 322A′ defined by porous catalytic rotor 385A′. One end 325′ offeed inlet line 320′ is in fluid communication with interior space 322A′of catalytic centrifuge 310′. In embodiments, outlet end 325′ of feedinlet line 320′ is positioned within a vertically central portion ofinterior space 322A′. Desirably, outlet end 325′ is positioned proximalto axis of rotation 303. In embodiments, the outlet end 325′ and/or theother (inlet) end of feed inlet line 320′ has a diameter of ½ inch, ¾inch, or 1-inch. System 300 further comprises an additional inlet line370 in fluid communication with interior space 322B′ between outer wall386A′ of inner porous catalytic rotor 385A′ and inner wall 388B′ ofouter porous catalytic rotor 385B′. Such a configuration may be usefulfor adding additional reactant, inert, or water vapor 375 into interiorspace 322B′. In embodiments, the outlet end of additional inlet line 370is positioned horizontally between outer wall 386A′ of inner rotor 385A′and inner wall 388B′ of outer rotor 385B′. In embodiments, the outletend of inlet line 370 is positioned below top 389B′ of outer rotor385B′. In embodiments, the outlet end of inlet line 370 is positionedbelow top 389A′ of outer rotor 385A′. In embodiments, the outlet end ofinlet line 370 is vertically positioned above top 389A′ of inner rotor385A′ and below top 389B′ of outer rotor 385B′.

The catalytic centrifugation system of this disclosure further comprisesa motor coupled to the at least one porous catalytic rotor of the atleast one catalytic centrifuge and configured to provide rotation of theat least one porous catalytic rotor about an axis of rotation. Rotationof the rotor(s) applies reactive centrifugal force to the feed gaswithin the rotor(s). In the embodiment of FIG. 1, for example, motor 145is coupled to rotor 185 and is capable of rotating rotor 185 about axisof rotation 103. In the embodiment of FIG. 2, motor 245 is coupled torotors 285A and 285B and is capable of rotating the rotors about axis ofrotation 203. In the embodiments of FIGS. 3A, 3B, and 3C, motors 345,345′, 345″ are coupled respectively to rotors 385A, 385A′, 385A″ and385B, 385B′, 385B″ and are capable of rotating the rotors about axis ofrotation 303, 303′, 303″. In embodiments in which a catalytic centrifugecomprises two or more rotors, one or more rotor may be rotatable in adirection opposite to that of at least one other rotor. For example, inthe embodiment of FIG. 2, inner rotor 285A and outer rotor 285B may becoupled to motor 245 via gears such that inner rotor 285A is rotatablein a clockwise direction and outer rotor 285B is rotatable in acounter-clockwise direction. The high speed motor may be capable ofrotational frequencies of up to 90,000 RPM. Alternatively, some othermeans may provide the high rotational frequency. In embodiments, thehigh speed motor is capable of producing rotational frequencies of atleast 5-, 7-, 7.5-, 10-, 15-, 20-, 25-, 30-, 40-, 50-, 60-, 70-, 80-, or90-thousand revolutions per minute (RPM).

Each of the one or more catalytic centrifuges of the disclosed systemfurther comprises at least one product outlet line configured forremoving product of a desired gaseous reaction from the catalyticcentrifuge. In the embodiment of FIG. 1, system 100 comprises productoutlet line 190. The inner surface of casing 165 and the outer surface186 of porous catalytic rotor 185 create an annular region 105therebetween. Product outlet line 190 comprises one (inlet) end 192 influid communication with annular space 105. End 192 of product outletline 190 may be vertically positioned anywhere within annular space 105,for example, towards the top, bottom, or center of annular region 105.In embodiments, end 192 of product outlet line 190 is positionedproximal the inner surface of casing 165. Alternatively, end 192 ofproduct outlet line 190 is positioned distal the inner surface of casing165. Alternatively, end 192 of product outlet line 190 is horizontallypositioned substantially between the inner surface of casing 165 andouter surface 186 of rotor 185. In embodiments, inlet end 192 and/or theother (outlet) end of product outlet line 190 has a diameter of ½ inch,¾ inch, or 1-inch.

In the embodiment of FIG. 2, catalytic centrifuge 210 of system 200comprises product outlet line 290. The inner surface of casing 265 andthe outer surface 286B of outer porous catalytic rotor 285B create anannular space 205 therebetween. Product outlet line 290 is configuredfor removal of reaction product from annular space 205. Product outletline 290 comprises one (inlet) end 292A in fluid communication withannular space 205. End 292A of product outlet line 290 may be verticallypositioned anywhere within annular space 205, for example, towards thetop, bottom, or center of annular region 205. In embodiments, end 292Aof product outlet line 290 is positioned proximal the inner surface ofcasing 265. Alternatively, end 292A of product outlet line 290 ispositioned distal the inner surface of casing 265. Alternatively, end292A of product outlet line 290 is horizontally positioned substantiallybetween the inner surface of casing 265 and outer surface 286B of outerrotor 285B. In embodiments, inlet end 292 and/or the other (outlet) endof product outlet line 290 has a diameter of ½ inch, ¾ inch, or 1-inch.

Each of the one or more catalytic centrifuges of the disclosed systemmay further comprise one or additional product outlet lines configuredfor removing product of the desired gaseous reaction from the catalyticcentrifuge. As indicated in the embodiment of FIG. 3A, for example, acatalytic centrifuge 310 may comprise a product outlet line 390configured for removal of reaction product from annular space 305.Product outlet line 390 comprises one (inlet) end 392 in fluidcommunication with annular space 305. End 392 of product outlet line 390may be vertically positioned anywhere within annular space 305, forexample, towards the top, bottom, or center of annular region 305. Inembodiments, end 392 of product outlet line 390 is positioned proximalthe inner surface of casing 365. Alternatively, end 392 of productoutlet line 290 is positioned distal the inner surface of casing 365.Alternatively, end 392 of product outlet line 390A is horizontallypositioned substantially between the inner surface of casing 365 andouter surface 386B of rotor 385B. Catalytic centrifuge 310 furthercomprises an outlet line 380 configured for removal of reaction productfrom interior space 322A. Product outlet line 380 comprises one (inlet)end in fluid communication with interior space 322A. The inlet end ofproduct outlet line 380 is positioned coincident with the axis ofrotation 303. The inlet end of product line 380 may be verticallypositioned toward the top 389A, the bottom 384 or the center of interiorspace 322A.

As indicated in the embodiment of FIG. 3C, a catalytic centrifuge 310″may comprise a product outlet line 390″ configured for removal ofreaction product from annular space 305″. Product outlet line 390″comprises one (inlet) end 392″ in fluid communication with annular space305″. End 392″ of product outlet line 390″ may be vertically positionedanywhere within annular space 305″, for example, towards the top,bottom, or center of annular region 305″. In embodiments, end 392″ ofproduct outlet line 390″ is positioned proximal the inner surface ofcasing 365″. Alternatively, end 392″ of product outlet line 390″ ispositioned distal the inner surface of casing 365″. Alternatively, end392″ of product outlet line 390″ is horizontally positionedsubstantially between the inner surface of casing 365″ and outer surface386B″ of outer rotor 385B″. Catalytic centrifuge 310″ further comprisesan additional outlet line 380′ configured for removal of reactionproduct from interior space 322B″. Product outlet line 380′ comprisesone (inlet) end in fluid communication with interior space 322B″. Theinlet end of product outlet line 380′ may be vertically positioned belowtop 389B″ of outer rotor 385B″. The inlet end of product outlet line380′ may be vertically positioned below top 389A″ of outer rotor 385A″.In embodiments, the inlet end of product outlet line 380′ in fluidcommunication with interior space 322B″ is positioned vertically betweenthe top 389A″ and top 389B″ of rotors 385A″ and 385B″ respectively. Theinlet end of product outlet line 380′ may be horizontally positionedbetween outer wall 386A″ of inner rotor 385A″ and inner wall 388B″ ofouter rotor 385B″.

The reactive centrifugation system may further comprise one or morepumps. The one or more pumps may be used to pressurize the catalyticcentrifuge and enhance flow therethrough. For example, in theembodiments of FIGS. 1 and 2, reactive centrifugation systems 100 and200 respectively comprise two pumps, 111A/111B and 211A/211Brespectively. Pump 111A/211A is positioned on feed inlet line 120/220and may serve to force feed materials into catalytic centrifuge 110/210under pressure. Pump 111B/211B may be positioned on product outlet line190/290 and may serve to provide vacuum removal of product from annularspace 105/205.

The system may comprise more than two pumps. For example, system 300 ofFIG. 3A comprises three pumps, 311A, 311B, and 311C. Pump 311A ispositioned on feed inlet line 320 and may serve to force feed materialsinto catalytic centrifuge 310 under pressure. Pump 311B may bepositioned on product outlet line 390 and may serve to provide vacuumremoval of product from annular space 305. A pump 311C may be positionedon a second product outlet line 383 and serve to remove product frominterior space 322A under vacuum.

In the embodiment of FIG. 3B, system 300′ comprises three pumps, 311A′,311B′, and 311D. Pump 311A′ is positioned on feed inlet line 320′ andmay serve to force feed materials into catalytic centrifuge 310′ underpressure. Pump 311B′ may be positioned on product outlet line 390′ andmay serve to provide vacuum removal of product from annular space 305′.A pump 311D may be positioned on second reactant inlet line 375 andserve to introduce a component into interior space 322B′ under pressure.

In the embodiment of FIG. 3C, system 300″ comprises three pumps, 311A″,311B″, and 311C′. Pump 311A″ is positioned on feed inlet line 320″ andmay serve to force feed materials into catalytic centrifuge 310″ underpressure. Pump 311B″ may be positioned on product outlet line 390″ andmay serve to provide vacuum removal of product from annular space 305″.A pump 311C′ may be positioned on a second product outlet line 380′ andserve to remove product from interior space 322B″ via vacuum.

Heaters. It is envisaged that, for certain applications, all or portionsof catalytic centrifuge 110, 210, 310 may be heated to enhance reactionof gaseous components. For example, all or portions of casing 165, 265,365 may be heated using apparatus and methods as known in the art.

The system of this disclosure may comprise two or more reactivecentrifuges. The two or more reactive centrifuges may be configured inseries and/or in parallel. In embodiments, a first reactive centrifugeof the system comprises a porous catalytic rotor having a firstcatalytic property while a second catalytic centrifuge of the seriescomprises a porous catalytic rotor having a second catalyticfunctionality. In embodiments, the product gas from a first catalyticcentrifuge is introduced as feed gas into a second catalytic centrifugecomprising a rotor with a different catalytic functionality. In suchembodiments, inter-stage gas addition is envisioned. Systems comprisingcatalytic centrifuges comprising two or more porous catalytic rotors andsystems comprising multiple catalytic centrifuges in series may beoperable to perform multiple reactions and/or enhance the extent of adesired reaction. The reactor can be configured with multiple porousrotating centrifuges within one reactor. In embodiments, rotating porouscylinders of differing diameters are configured to rotate clockwise orcounterclockwise around one another. Each rotating porous cylinder canhave the same or a different catalytic surface to catalyze the same or adifferent reaction. In such embodiments, it is envisioned thatadditional feed (i.e. gas) can be introduced into the annular spacebetween the rotating porous cylinders as desired.

III. Production of Desired Product by Reactive Centrifugation. A methodof producing desired product of gas phase reaction according to thisdisclosure will now be made with reference to FIG. 1. A gaseous feed 115is introduced into catalytic centrifuge 110 via feed inlet line 120. Thefeed gas is introduced via inlet line 120 into interior space 122contained within the walls of catalytic rotor 185. In embodiments, thefeed gas is introduced to a vertically central portion of interior space122. The feed gas is introduced into interior region 122 proximal axisof rotation 103. Motor 145 causes rotation of porous catalytic rotor 185about axis of rotation 103. The porous catalytic rotor may be rotated ata rotational frequency of up to at least 5-, 7-, 7.5-, 10-, 15-, 20-,25-, 30-, 40-, 50-, 60-, 70-, 80-, or 90-thousand RPM. Reactivecentrifugal force is applied to the gas introduced into catalyticcentrifuge 110, forcing the gas into the pores of porous catalytic rotor185.

As discussed hereinabove porous catalytic rotor 185 is made of orcontains porous catalytic material through which gas must pass in orderto enter annular region 105 of catalytic centrifuge 110. The pores ofthe rotor may be tailored to provide optimal surface area forinteraction of gas feed with catalyst. Within porous catalytic rotor185, the feed gas encounters catalytic material at a high velocity andhigh rate of shear. At sufficiently high rotational frequencies, feedgas may break prior to entering the catalytic rotor, for example, carbondioxide may break into carbon monoxide and highly reactive oxygen priorto entering catalytic rotor 185. The operating temperature and pressuremay be selected based on the desired reaction. In applications, theoperating temperature may be in the range of from about room temperatureto about 600° C. In applications, the operating temperature is in therange of from about 100° C. or 150° C. to about 300° C., 400° C., or500° C. The pressure may be a desired pressure within the limits of thedesign materials.

The feed gas may comprise one or more of hydrogen, methane, ethane,propane, butane, carbon dioxide, carbon monoxide, H₂O, another inert gasor hydrocarbon gas or another gaseous reactant. Higher molecular weightcomponents may be produced from these components via the disclosedmethod. Utilization of high temperatures may allow gas phase reaction ofproducts which are not gaseous at room temperature. For example,utilization of elevated temperature may allow feed gas comprisinggaseous gasoline or diesel. Such a feed gas may be desulfurized at hightemperature (400° C. to 500° C.) and the catalytic rotor may comprisedesulfurization catalyst. The feed gas may further comprise H₂O and/orinerts in addition to reactant gas. Inert gas may be selected from, forexample, helium and nitrogen. The introduction of H₂O with the feed gasmay be used, for example, to provide hydrogen reactant. Due to theutilization of a catalytic centrifuge, a greater surface area ofcatalyst and thus more catalyst available for promoting reaction mayallow operation of various reactions at lower temperatures and/orpressures than conventionally allowed.

Under certain pressure/temperature conditions the gas and/or conversionproducts may be converted to liquid in the reactor. In some instances aliquid may be fed to the reactor and converted to a gas under cavitationconditions as it is fed through the reactor. The extreme temperaturesand pressures created during cavitation in combination with the presenceof a catalytic surface may be expected to enhance chemical reactionsaccordingly.

Pump 111A may be used to apply pressure and force feed gas 115 intorotor 185. Within porous catalytic rotor 185, gas interacts with thecatalyst and other gas molecules. Reaction product 195 is removed fromannular space 105 via one or more outlet lines 190. Vacuum may beapplied to annular space 105 via pump 111B, enhancing withdrawal ofproduct via product outlet line 190. In embodiments, pump 111A and line120 are used to remove undesired impurities from interior space 122 byapplication of vacuum.

Another method of producing a desired product will now be made withreference to FIG. 2. Gaseous feed 215 is introduced into catalyticcentrifuge 210 via feed inlet line 220. The feed gas is introduced viainlet line 220 into interior space 222A contained within the walls ofinner porous catalytic rotor 285A. In embodiments, the feed gas isintroduced to a vertically central portion of interior space 222A. Thefeed gas is introduced into interior region 222A proximal axis ofrotation 203. Motor 245 causes rotation of inner porous catalytic rotor285A about axis of rotation 203. The porous catalytic rotor may berotated at a rotational frequency of up to 5-, 7-, 7.5-, 10-, 15-, 20-,25-, 30-, 40-, 50-, 60-, 70-, 80-, or 90-thousand RPM. Reactivecentrifugal force is applied to the gas introduced into catalyticcentrifuge 210, forcing the gas into the pores of inner porous catalyticrotor 285A. As discussed hereinabove inner porous catalytic rotor 285Ais made of or contains a first porous catalytic material through whichgas must pass in order to enter interior space 222B between outersurface 286A of inner catalytic rotor 285A and inner surface 288B ofouter porous catalytic rotor 285B. First porous catalytic materialcomprises a first catalyst. The pores of inner rotor 285A may betailored to provide optimal interaction of gas feed with the firstcatalyst. Within inner porous catalytic rotor 285A, the feed gasencounters the first catalytic material at a high rate of shear. Pump211A may be used to apply pressure and force feed gas into inner porouscatalytic rotor 285A. Within inner porous catalytic rotor 285A, feed gasinteracts with the first catalyst and other gas molecules. A firstproduct passing out of inner catalytic rotor 285A enters interior space222B.

Gas entering second interior space 222B enters outer porous catalyticrotor 285B. As discussed hereinabove outer porous catalytic rotor 285Bis made of or contains a second porous catalytic material through whichgas must pass in order to enter annular space 205 between outer surface286B of outer catalytic rotor 285B and the inner surface of casing 265.Second porous catalytic material comprises a second catalyst. The secondcatalyst may be the same as or different from the first catalyst. Thepores of outer rotor 285B may be tailored to provide optimal interactionof gas introduced therein with the second catalyst. Within outer porouscatalytic rotor 285B, the gas encounters the second catalytic materialat a high rate of shear. Within outer porous catalytic rotor 285B, gasinteracts with the second catalyst to produce a second product. A secondproduct passes out of outer catalytic rotor 285B and enters annularspace 205. The second product may be the same as or different from thefirst product.

Second reaction product 295 is removed from annular space 205 via one ormore outlet lines 290. Vacuum may be applied to annular space 205 viapump 211B, enhancing withdrawal of second product 295 via second productoutlet line 290.

Another method of producing a desired product will be made withreference to FIG. 3A. Gas feed 315 is introduced into catalyticcentrifuge 310 via feed inlet line 320. The feed gas is introduced viainlet line 320 into interior space 322B between the outer wall 386A ofinner porous catalytic rotor 385A and inner wall 388B of outer catalyticrotor 385B. The feed gas may be introduced at a location below top 389Bof outer rotor 385B and substantially horizontally between outer surface386A of inner rotor 385A and inner surface 388B of outer rotor 385B.Pump 311A may be used to introduce feed gas into interior space 322Bunder pressure.

Motor 345 causes rotation of inner porous catalytic rotor 385A and outercatalytic rotor 385B about axis of rotation 303. The rotors may rotatein the same or opposite direction about axis of rotation 303. The porouscatalytic rotors may be rotated at a rotational frequency of up to 5-,7-, 7.5-, 10-, 15-, 20-, 25-, 30-, 40-, 50-, 60-, 70-, 80-, or90-thousand RPM. Gas passing into inner rotor 385A may be converted to afirst product 383 which exits inner rotor 385A into interior space 322A.Vacuum 311C may be used to enhance extraction of first product frominterior space 322A. Gas passing into outer rotor 385B may be convertedto a second product 395 which may enter annular region 305. Vacuum 311Bmay be used to enhance extraction of second product 395 from annularregion 305. Via application of pressure to line 390, gas may be giventime to enter inner rotor 385A. Via application of pressure to line 380,gas may be forced through outer rotor 385B. Assist of vacuum and/orpressure may be utilized to control the desired reaction. In thismanner, two different reactions having two different products may beperformed substantially simultaneously.

Description of another method of producing product via gaseous reactionwill now be made with reference to FIG. 3B. Gaseous feed 315′ isintroduced into catalytic centrifuge 310′ via feed inlet line 320′. Thefeed gas is introduced via inlet line 320′ into interior space 322A′contained within the walls of inner porous catalytic rotor 385A′. Inembodiments, the feed gas is introduced to a vertically central portionof interior space 322A′. The feed gas is introduced into interior region322A′ proximal axis of rotation 303′. Motor 345′ causes rotation ofinner porous catalytic rotor 385A′ about axis of rotation 303′. Theporous catalytic rotor may be rotated at a rotational frequency of up toat least 5-, 7-, 7.5-, 10-, 15-, 20-, 25-, 30-, 40-, 50-, 60-, 70-, 80-,or 90-thousand RPM. Reactive centrifugal force is applied to the gasintroduced into catalytic centrifuge 310′, forcing the gas into thepores of inner porous catalytic rotor 385A′. As discussed hereinaboveinner porous catalytic rotor 385A′ is made of or contains a first porouscatalytic material through which gas must pass in order to enterinterior space 322B′ between outer surface 386A′ of inner catalyticrotor 385A′ and inner surface 388B′ of outer porous catalytic rotor385B′. First porous catalytic material comprises a first catalyst. Thepores of inner rotor 385A′ may be tailored to provide optimalinteraction of gas feed with the first catalyst. Within inner porouscatalytic rotor 385A′, the feed gas encounters the first catalyticmaterial at a high rate of shear. Pump 311A′ may be used to applypressure and force feed gas into inner porous catalytic rotor 385A′.Within inner porous catalytic rotor 385A′, feed gas interacts with thefirst catalyst and other gas molecules. A first product passing out ofinner catalytic rotor 385A′ enters interior space 322B′.

Gas entering second interior space 322B′ enters outer porous catalyticrotor 385B′. Additional feed may be introduced as desired. As discussedhereinabove outer porous catalytic rotor 385B′ is made of or contains asecond porous catalytic material through which gas must pass in order toenter annular space 305′ between outer surface 386B′ of outer catalyticrotor 385B′ and the inner surface of casing 365′. Second porouscatalytic material comprises a second catalyst. The second catalyst maybe the same as or different from the first catalyst. The pores of outerrotor 385B′ may be tailored to provide optimal interaction of gasintroduced therein with the second catalyst. Within outer porouscatalytic rotor 385B′, the gas encounters the second catalytic materialat a high rate of shear. Within outer porous catalytic rotor 385B′, gasinteracts with the second catalyst to produce a second product. A secondproduct passes out of outer catalytic rotor 385B′ and enters annularspace 305′. The second product may be the same as or different from thefirst product. Additional reactant 375 may be introduced into interiorspace 322B′ via additional inlet line 370. Pump 311D may be used tointroduce the additional reactant under pressure.

Second reaction product 395′ is removed from annular space 305′ via oneor more outlet lines 390′. Vacuum may be applied to annular space 305′via pump 311B′ to enhance withdrawal of second product via secondproduct outlet line 390′. The second product may be the same ordifferent from the first product.

As a modification to this process in which a configuration as in FIG. 3Cis utilized, first product 383′ may be removed from interior space 322B″via additional outlet line 380′. Pump 311C′ may serve to enhance removalof product 383′ via additional outlet line 380′.

The catalytic centrifugation process utilizes a design that allows gasto constantly flow in and out of catalytic centrifuge. Unlike mostcentrifuges which rely on batch processing, the disclosed catalyticcentrifuge allows continuous or semi-continuous processing. In suchapplications, product may be continuously or semi-continuously extractedfrom annular regions and/or interior spaces via one or more outletlines. In applications, an additional inlet line and an additionaloutlet line are both in fluid communication with interior space betweenthe inner and outer rotors.

The catalytic centrifuge is designed for operation at a temperaturespecific to the reaction desired. Although not intended to be limiting,the reaction may be performed at a temperature in the range of fromabout 25° C. to about 600° C. In embodiments, reaction is performed atroom temperature. By operating at elevated temperature, gas phasereactions of components which are normally liquids at room temperaturecan be performed via the disclosed system and method. For example,utilization of high temperature may allow reactions with diesel andgasoline.

Serial Operation. In embodiments of the gas reaction method, product gasfrom a first reactive centrifuge is introduced directly into a secondcatalytic centrifuge as feed gas thereto, while the product gas is stillin reactive form. A fresh external feed gas may also be added to thereactive product gas. In this manner, serial and complex reactions maybe performed.

Features/Advantages. Utilization of the disclosed system and method mayallow conversion of a substantial amount of the rotational energy of therotors to one or more desired reactions. In applications, the system andmethod allow greater than about 95% conversion of energy to reaction;alternatively, greater than about 97% conversion; alternatively, greaterthan about 99% conversion.

EXAMPLES Example 1

A system comprising a catalytic centrifuge comprising a rotor catalyticfor hydrodenitrogenation, hydrodesulfurization, or hydrodeoxygenationmay be used to desulfurize, denitrogenate, and/or deoxygenate a feedgas.

Example 2

In embodiments, a catalytic rotor comprises reforming catalyst. Forexample, the rotor may comprise a catalyst effective for methanereforming or a catalyst effective for steam methane reforming. Suitablecatalyst may be, for example, nickel copper catalyst or nickel silicacatalyst. In such embodiments, feed gas comprising methane and carbondioxide, or methane, carbon dioxide, and steam may be reformed toproduce synthesis gas.

Synthesis gas may be introduced at high temperature into a catalyticcentrifuge or a second rotor comprising catalyst effective forFischer-Tropsch conversion of synthesis gas into hydrocarbons. In thismanner, higher hydrocarbons may be produced via the disclosed system andmethod. The disclosed system and process may enhance the performanceand/or alter the product distributions of Fischer-Tropsch processes byenhancing contact time of catalyst and synthesis gas.

Alternatively or additionally, synthesis gas may be passed through acatalytic centrifuge or a rotor of a catalytic centrifuge of thisdisclosure having catalytic functionality for the production of mixedalcohols from synthesis gas. In such applications, the disclosed systemand method may be used to improve the selectivity and rate of reactionfor the production of mixed alcohols from synthesis gas.

Example 3

Feed gas comprising steam, methane, and carbon dioxide may be used toproduce alcohols, aldehydes or other desired product. The presence ofwater above the boiling point (i.e., steam) may serve to provide oxygenand hydrogen to this and other reactions.

Example 4

In embodiments, a catalytic rotor of a catalytic centrifuge compriseshydrogenation catalyst. In this manner, the disclosed system and methodmay be used to hydrogenate, for example, acetylene to ethylene, orhydrogenate propadiene to other olefins and/or paraffins. Acetylenes anddienes are undesired products produced in the cracking of ethane,propane and higher molecular weight hydrocarbons. Aromatics are alsoproduced in high temperature cracking of naphthalene. Some of thesearomatics may be hydrogenated or oxidized to carbon oxides via thedisclosed system and method.

Example 5

World-wide, acetic acid is produced from methanol by carbonylation, i.e.methanol plus carbon dioxide using a ruthenium-based catalyst. (Whencobalt is used, the pressures are on the order of 6000 psi, but for theruthenium catalyst the pressure decreases to 1500 psi.) In embodiments,the system and process of the present disclosure are used to produceacetic acid via reaction of methanol and carbon dioxide.

Example 6

Ethanol production by the reaction of methanol with carbon dioxide andhydrogen may also benefit from the use of the presently-disclosed systemand process.

Example 7

Reaction of methane with olefins, dienes, or aromatics to produce highermolecular weight products.

Example 8

Reaction of carbon dioxide with water (steam) to produce sugars.

Example 9

Reaction of alcohols, aldehydes and or ketones to produce olefins and orhigher molecular weight hydrocarbons typical of synthetic fuels such asjet fuel, kerosene, gasoline and or diesel fuel. More specific examplesare methanol converted to low molecular weight olefins such as ethyleneand propylene by using the catalyst, SAPO-34. The use of H-ZSM-5 and theappropriate temperatures, gasoline and diesel fuel may be produced frommethanol.

Example 10

Partial oxidation of methane may be conducted and depending on thecatalyst and reaction conditions various products may be produced.Predominately ethylene might be produced by the reaction referred to inthe patent and open literature as oxidative coupling of methane. At yeta different set of conditions and catalyst methanol may be produce.

Example 11

Partial oxidation of ethane to produce ethylene and/or acetic acid byuse of the appropriate catalyst and set of reaction temperature,pressure, and residence time.

While preferred embodiments of the invention have been shown anddescribed, modifications thereof can be made by one skilled in the artwithout departing from the spirit and teachings of the invention. Theembodiments described herein are exemplary only, and are not intended tobe limiting. Many variations and modifications of the inventiondisclosed herein are possible and are within the scope of the invention.Where numerical ranges or limitations are expressly stated, such expressranges or limitations should be understood to include iterative rangesor limitations of like magnitude falling within the expressly statedranges or limitations (e.g., from about 1 to about 10 includes, 2, 3, 4,etc.; greater than 0.10 includes 0.11, 0.12, 0.13, and so forth). Use ofthe term “optionally” with respect to any element of a claim is intendedto mean that the subject element is required, or alternatively, is notrequired. Both alternatives are intended to be within the scope of theclaim. Use of broader terms such as comprises, includes, having, etc.should be understood to provide support for narrower terms such asconsisting of, consisting essentially of, comprised substantially of,and the like.

Accordingly, the scope of protection is not limited by the descriptionset out above but is only limited by the claims which follow, that scopeincluding all equivalents of the subject matter of the claims. Each andevery claim is incorporated into the specification as an embodiment ofthe present invention. Thus, the claims are a further description andare an addition to the preferred embodiments of the present invention.The disclosures of all patents, patent applications, and publicationscited herein are hereby incorporated by reference, to the extent theyprovide exemplary, procedural or other details supplementary to thoseset forth herein.

We claim:
 1. An apparatus comprising: a first porous rotor positionedabout an axis of rotation, wherein the first porous rotor comprises afirst catalyst; a second porous rotor concentric with the first porousrotor, wherein the second porous rotor comprises a second catalyst; anouter casing, wherein the outer casing and the first porous rotor areseparated by an annular space; and a motor configured for rotating thefirst porous rotor about the axis of rotation.
 2. The apparatus of claim1, the apparatus further comprising: a feed inlet line; and a firstoutlet line, wherein the first outlet line is in fluid communicationwith the annular space.
 3. The apparatus of claim 2, wherein the feedinlet line is fluidly connected with the interior space, and wherein thefirst porous rotor is positioned surrounding an interior space.
 4. Theapparatus of claim 3, wherein the first porous rotor comprises aselectively permeable material.
 5. The apparatus of claim 4, wherein theselectively-permeable material is made with, impregnated with, or coatedwith an additional catalyst.
 6. The apparatus of claim 5, wherein theselectively-permeable material comprises sintered metal or ceramic. 7.The apparatus of claim 3, wherein the feed inlet line extends into theinterior space.
 8. The apparatus of claim 7, wherein the feed inlet lineextends into a vertically central portion of the interior space.
 9. Theapparatus of claim 1, the apparatus further comprising a feed inlet linefluidly connected with the interior space, and wherein the second porousrotor is positioned surrounding a second interior space.
 10. Theapparatus of claim 9, the apparatus further comprising an outlet line,wherein the outlet line is fluidly connected with the second interiorspace.
 11. The apparatus of claim 1, wherein the first catalyst and thesecond catalyst are the same.
 12. The apparatus of claim 1, wherein thefirst catalyst and the second catalyst are different.
 13. A systemcomprising a plurality of the apparatus of claim
 1. 14. A method ofproducing a product of a gaseous reaction, the method comprising:contacting a feed gas comprising at least one gaseous reactant with arotor wherein the rotor is permeable to the at least one gaseousreactant, and wherein the rotor comprises a catalyst effective forcatalyzing the gaseous reaction; extracting the product from an outletside of the rotor; and passing the product through a second rotor froman inlet side, wherein the second rotor is permeable to the product, andwherein the second rotor is made from or contains additional catalysteffective for catalyzing a second reaction.
 15. The method of claim 14,the method further comprises rotating the rotor about an axis ofrotation at a rotational frequency.
 16. The method of claim 15, whereinthe rotor is cylindrical and porous.
 17. The method of claim 16, whereinthe rotor comprises sintered metal or ceramic.
 18. The method of claim17, wherein the sintered metal or ceramic is made with, impregnatedwith, or coated with catalyst.